Airfoil assembly and method of forming same

Abstract

An airfoil or vane for a combustive power plant includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material having continuous fibers. The first composite material is different from the second composite material. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. A method of fabrication includes injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the core and platforms of an airfoil assembly. The injected thermoplastic fiber composite material is then cured in the mold. The cured thermoplastic fiber composite material is then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the core material. The surface plies are then compressed and cured in a mold.

1. An airfoil for a combustive power plant, the airfoil comprising:
 an inner core formed from a first polymeric composite material having discontinuous fibers, said inner core defining a platform portion integrally formed with a vane portion protruding from said platform portion; 
 an outer sleeve formed from a second polymeric composite material having continuous fibers; 
 the outer sleeve generally surrounding and being connected to the vane portion of the inner core without surrounding the platform portion. 
 
     
     
       2. An airfoil as defined in  claim 1 , wherein the first composite material includes a thermoplastic material. 
     
     
       3. An airfoil as defined in  claim 1 , wherein the first composite material includes an injection molded thermoplastic material. 
     
     
       4. An airfoil as defined in  claim 1 , wherein the first composite material includes a nylon material having about 30% chopped fibers. 
     
     
       5. An airfoil as defined in  claim 1 , wherein the second composite material includes a long fiber thermoset material. 
     
     
       6. An airfoil as defined in  claim 1 , wherein the second composite material includes a long fiber thermoplastic material. 
     
     
       7. An airfoil as defined in  claim 1 , wherein the continuous fibers include carbon fiber. 
     
     
       8. An airfoil as defined in  claim 1 , wherein the outer sleeve includes a plurality of plies of the second composite material. 
     
     
       9. An airfoil as defined in  claim 1 , wherein the outer sleeve includes three plies of the second composite material. 
     
     
       10. A vane for use in a combustive power plant, the vane comprising:
 an inner core formed from a synthetic polymer material and having discontinuous fibers, said inner core defining a platform portion and a vane portion integrally connected with the platform portion; 
 an outer sleeve formed from a polymer composite material including long fiber carbon material; and 
 wherein the outer sleeve substantially surrounds and is connected to the vane portion of the inner core without surrounding the platform portion. 
 
     
     
       11. A vane as defined in  claim 10 , wherein the synthetic polymer material includes a thermoplastic material. 
     
     
       12. A vane as defined in  claim 10 , wherein the synthetic polymer material includes an injection molded thermoplastic material. 
     
     
       13. A vane as defined in  claim 10 , wherein the synthetic polymer material includes a nylon material having about 30% chopped fiber. 
     
     
       14. A vane as defined in  claim 10 , wherein the long fiber carbon material includes a thermoset material. 
     
     
       15. A vane as defined in  claim 10 , wherein the long fiber carbon material includes a thermoplastic composite material. 
     
     
       16. A vane as defined in  claim 10 , wherein the outer sleeve includes a plurality of plies of the long fiber carbon material. 
     
     
       17. A vane as defined in  claim 10 , wherein the outer sleeve includes three plies of the long fiber carbon material.